I haven't built a brute, but I have halved a tj using AEV's method as outlined in the brute build instructions. If it were me I would not attempt to chemically strip the line-X. Just use an angle grinder with a knotted wire brush and wear it down an inch or two from the cuts/ welds. After welding hit it with the grinder again to remove any scorched liner. When you are ready for paint, take it back to line-x and have the entire close out interior lined.
Also, the disassembly is kind rough on the discarded part of the tub. I would consider the rear part of the tub (from the rear axle back, not from the waterfall) to be useful for building a trailer. Primarily as a close out for another tj tub.

After reading through your build, and looking at that pic of the T1 22" stretch, I'm beginning to think that the 15" stretch with a Brute hardtop and custom bulkhead could be pretty sweet.

Wouldn't you prefer to start with a clean Jeep than one that's jacked up?

No offense to any of us, but TJ's are hardly collectable vehicles. If we were talking about a collectable car (or one that has potential to be collectable like a Rubicon LJ maybe), then definitely, start with one that's already a mess because you're adding value, not destroying it by molesting a pristine vehicle.

But a regular TJ? I think I'd rather start with a nice clean rig than a messed up one... way less work!

Wouldn't you prefer to start with a clean Jeep than one that's jacked up?

No offense to any of us, but TJ's are hardly collectable vehicles. If we were talking about a collectable car (or one that has potential to be collectable like a Rubicon LJ maybe), then definitely, start with one that's already a mess because you're adding value, not destroying it by molesting a pristine vehicle.

But a regular TJ? I think I'd rather start with a nice clean rig than a messed up one... way less work!

Might be more work, but you could probably sell the nice TJ and pick up one that's a bit beat up for less, and have $$ to get you started with the kit, or tools that you don't have and will need, or just beer money or whatever.

I say that with one caveat. If you're not going to wheel it, and are just going to pick up groceries or take it to shows, or maybe take it on mild wheeling/camping trips, then yea cut up the nice jeep. If you're gonna wheel it hard, why start with a nice jeep? It's just gonna get beat up anyway.

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Yeah but I have zero rust, adult driven Tj that has all matching records with no broken bolts... It's tough to take a sawzall to. But, I never carry extra passengers and my backseat stays out 80% of the year. The truck bed for carrying gear is a plus and the smaller cab keeps the ac in better and way less road noise- plus, it's still a jeep!

I would keep lift at 3 inches with metalcloak flares front and rear which I already have. That and a front metal cloak bumper with a custom rear bumper would be my brute touches. I could even turbo the 2.5 and have a modern Tj Comanche wanna be!

Wouldn't you prefer to start with a clean Jeep than one that's jacked up?

No offense to any of us, but TJ's are hardly collectable vehicles. If we were talking about a collectable car (or one that has potential to be collectable like a Rubicon LJ maybe), then definitely, start with one that's already a mess because you're adding value, not destroying it by molesting a pristine vehicle.

But a regular TJ? I think I'd rather start with a nice clean rig than a messed up one... way less work!

Agreed. Although my Jeep looks pretty good now, it started off as a stock black Sport a few years back. I'm not so concerned with cutting up the Jeep. I just really want to walk through my options to make this build as well thought out as possible. Honestly, I'm beginning to reconsider the Brute build and thinking about the possibility of a 15" to 22" tub stretch. Maybe I'll land somewhere in between and go for 18.7" of stretch to create a 112" wheelbase like AEV used to produce and use the Brute hardtop to create a TJ Scrambler of sorts?

Agreed. Although my Jeep looks pretty good now, it started off as a stock black Sport a few years back. I'm not so concerned with cutting up the Jeep. I just really want to walk through my options to make this build as well thought out as possible. Honestly, I'm beginning to reconsider the Brute build and thinking about the possibility of a 15" to 22" tub stretch. Maybe I'll land somewhere in between and go for 18.7" of stretch to create a 112" wheelbase like AEV used to produce and use the Brute hardtop to create a TJ Scrambler of sorts?

That's an option but if I were going to spend money to have it done I'd go with the clean look of the brute kit. Just hard to beat the mean look of them.

I rarely have time to get to this site but because a Brute conversion is something I've drooled over, I wanted to check out this thread. Here are my thoughts:

-From a practical standpoint (yes, even Jeep owners can be practical sometimes) the longer wheelbase can improve function. A slightly longer wheelbase helps with stability when climbing obstacles and doing some off camber maneuvers. It will handle better on the road and ride better overall. There is a slight downside if you do really tight wooded trails where a short wheelbase comes in very handy.

-I disagree with those suggesting to start with a beater. You will be investing $10k+ to do the conversion. Do you want to put that into a piece of junk? If you start with an older, high mileage, well worn Jeep that $10k will easily double. Once done you will want to do the rest of the bodywork so it looks good, instead of just a long wheelbase beater. Then you have a nice looking Jeep on the outside- need to do the interior to fix the worn seats ,beat up dash, etc. Of course that worn out engine will have to go, and better go through the brakes, axle seals, bearings, etc. Of course after all that you need some cool accessories, so add in bumpers, winch, tires, lift... You already have all that. If you really want a Brute conversion, do it to a nice Jeep you already know the history of.

Why be so cheap?
Wifey & I made a trip to Detroit area and went to the AEV dealer and seen 40 or so of them in various stages of development.
we wandered around there in amazement and awe!
Mouths wide open and drooling.

Talked to a salesman who went thru what costs what and Found out that for a mere $130,000.oo or so we could drive away with a brand new Bada$$ Brute!

We unloaded our cash and spent $3,000.oo for bumpers and a few do dads and what nots.

Loaded the Ford 150 up and off back to Canada with our boxes. They made us pay duty or customs whatever they call it and I took a couple of days in the dead of winter to install the upgrades.

OUTSTANDING products and fits PERFECTLY.
Happy Wifey and well worth the $$$ for the value.

If you have to ask well then ??
Like asking someone else if you should grow a mustache?

Don't be afraid of fear?
A grinder with a wire wheel will get rid of the lineX.
Hammer chisel or a air powered chisel and lots of elbow grease .
Yup lotsa a work .
BUT if the end result will be satisfaction!
Priceless.
those for sale Brutes will be around and DON'T EXPECT to make $$$ off of it when selling.
FUN FACTOR and PRIDE in the done it myself is where the benefits are.

You just need a PUSH to get past the point of no return .
And then you have to finish it.

PLUS when driving the embarrassing little ford around will give you more incentive to finish the project!